Heater & Air Conditioner

HEATER &
AIR CONDITIONER GI
SECTION HA MA
EM
LC
EC
CONTENTS FE
PRECAUTIONS ...............................................................2 A/C System................................................................30

CL
Supplemental Restraint System (SRS) ″AIR Intake Door ................................................................32
BAG″ ............................................................................2 Blower Motor..............................................................36 MT
Precautions for Working with HFC-134a (R-134a) .....2 Insufficient Cooling ....................................................43
General Refrigerant Precautions .................................3 Insufficient Heating ....................................................51
Precautions for Leak Detection Dye............................3 Air Mix Door...............................................................52 AT
Precaution for Identification Label on Vehicle .............3 Mode Door .................................................................59
Precautions for Refrigerant Connection ......................4 Bi-Level Door .............................................................62
Precautions for Servicing Compressor........................7 Magnet Clutch............................................................65
PD
Precautions for Service Equipment .............................7 Noise..........................................................................76
Wiring Diagrams and Trouble Diagnoses....................9 SERVICE PROCEDURE................................................77 AX
PREPARATION .............................................................10 HFC-134a (R-134a) Service Procedure ....................77
Special Service Tools ................................................10 Maintenance of Lubricant Quantity in
HFC-134a (R-134a) Service Tools and Compressor ...............................................................79 SU
Equipment..................................................................11 Compressor ...............................................................81
DESCRIPTION ...............................................................14 Compressor Clutch - DKV-11G (ZEXEL make).........82
Refrigeration System .................................................14 Thermal Protector ......................................................85 BR
Component Layout ....................................................15 Heater Unit (Heater Core) .........................................86
Control Operation ......................................................16 Blower Unit ................................................................88
ST
Discharge Air Flow.....................................................17 Cooling Unit (A/C Evaporator)...................................89
System Description....................................................18 Refrigerant Lines .......................................................90
TROUBLE DIAGNOSES................................................19 Fluorescent Dye Leak Detector.................................94 RS
Component Location..................................................19 Belt.............................................................................95
Circuit Diagram - Air Conditioner...............................21 Idle Air Control Valve (IACV) - Auxiliary Air
Wiring Diagram - A/C, Heater - .................................22 Control (AAC) Valve ..................................................95 BT
Wiring Diagram - A/C, M - .........................................23 A/C Control System ...................................................95
How to Perform Trouble Diagnoses for Quick Ventilation Air Filter....................................................96
and Accurate Repair ..................................................27 SERVICE DATA AND SPECIFICATIONS (SDS) .........98
Operational Check .....................................................28 Manual .......................................................................98
SC
EL
IDX
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG”
Supplemental Restraint System (SRS) “AIR

BAG” NMHA0270
The Supplemental Restraint System such as “AIR BAG” used along with a seat belt, helps to reduce the risk
or severity of injury to the driver and front passenger for certain types of collision. The SRS system composi-
tion which is available to NISSAN MODEL S15 is as follows:
The Supplemental Restraint System consists of driver air bag module (located in the center of the steering
wheel), front passenger air bag module (located on the instrument panel on passenger side), a diagnosis
sensor unit, warning lamp, wiring harness and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified with yellow harness connector.
Precautions for Working with HFC-134a
(R-134a) NMHA0061
WARNING:
I CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants
must never be mixed, even in the smallest amounts. If the refrigerants are mixed, a compressor
failure is likely to occur.
I Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor failure is likely to occur.
I The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
a) When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
b) When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as pos-
sible to minimize the entry of moisture into system.
c) Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
d) Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refriger-
ant. If accidental system discharge occurs, ventilate work area before resuming service. Additional
health and safety information may be obtained from refrigerant and lubricant manufacturers.
e) Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts.
Damage may result.
HA-2
PRECAUTIONS
General Refrigerant Precautions
General Refrigerant Precautions =NMHA0062

WARNING:
I Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the GI
refrigerant every time an air conditioning system is discharged.
I Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
MA
I Do not store or heat refrigerant containers above 52°C (125°F).
I Do not heat a refrigerant container with an open flame; if container warming is required, place the EM
bottom of the container in a warm pail of water.
I Do not intentionally drop, puncture, or incinerate refrigerant containers.
I Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. LC
I Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation. EC
I Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during repair. Some mixtures of air and R-134a have been
shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or FE
property damage. Additional health and safety information may be obtained from refrigerant manu-
facturers.
Precautions for Leak Detection Dye CL
NMHA0271
I The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultravio-
let (UV) lamp is required to illuminate the dye when inspecting for leaks. MT
I Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of
the fluorescent dye.
I A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal AT
should only be repaired after confirming the leak with an electronic refrigerant leak detector.
I Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a
future service.
PD
I Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period AX
of time cannot be removed.
I Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
I Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 cc) per A/C system. SU
I Leak detection dyes for R-134a and R12 A/C systems are different. Do not use R-134a leak detection dye
in R-12 A/C system or R-12 leak detection dye in R-134a A/C systems or A/C system damage may result.
I The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure
BR
occurs.
ST
RS
BT
Precaution for Identification Label on Vehicle NMHA0272

I Vehicles with factory installed fluorescent dye have this iden-
tification label on the under side of hood.
I Vehicles with factory installed fluorescent dye have a green
SC
label.
I Vehicles without factory installed fluorescent dye have a blue EL
label.
IDX
SHA436FA
HA-3
PRECAUTIONS
Precautions for Refrigerant Connection
Precautions for Refrigerant Connection NMHA0063

A new type refrigerant connection has been introduced to all refrigerant lines except the following portion.
I Expansion valve to cooling unit
FEATURES OF NEW TYPE REFRIGERANT CONNECTION NMHA0063S01
I The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-
nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.
I The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby
facilitating piping connections.
SHA815E
HA-4
PRECAUTIONS
Precautions for Refrigerant Connection (Cont’d)
O-RING AND REFRIGERANT CONNECTION NMHA0063S02
GI
MA
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LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
ZHA001H
BT
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse
O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
SC
EL
IDX
HA-5
PRECAUTIONS
O-Ring Part Numbers and Specifications NMHA0063S0201
Connection O-ring
Part number D mm (in) W mm (in)
type size
New 92471 N8210 6.8 (0.268) 1.85 (0.0728)

8
Former 92470 N8200 6.07 (0.2390) 1.85 (0.0728)
New 92472 N8210 10.9 (0.429) 2.43 (0.0957)

12
Former 92471 N8200 10.8 (0.425) 1.78 (0.0701)
New 92473 N8210 13.6 (0.535) 2.43 (0.0957)

16
Former 92473 N8200 13.9 (0.547) 1.78 (0.0701)
SHA814E New 92474 N8210 16.5 (0.650) 2.43 (0.0957)

19
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system
is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove
it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
I When the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber.
I When connecting tubes, always use a torque wrench and a back-up wrench.
I After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
I When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.
I Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
I Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
I Always replace used O-rings.
I When connecting tubes, apply lubricant to circle of the O-rings shown in illustration. Be careful
not to apply lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type R
Part number: KLH00-PAGR0
I O-ring must be closely attached to dented portion of tube.
I When replacing the O-ring, be careful not to damage O-ring and tube.
I Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
I After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten
connections of seal seat to the specified torque.
HA-6
PRECAUTIONS
GI
MA
EM
LC
EC
FE
RHA861F CL
Precautions for Servicing Compressor
I Plug all openings to prevent moisture and foreign matter from entering.
NMHA0064
MT
I When the compressor is removed, store it in the same position as it is when mounted on the car.
I When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres- AT
sor” exactly. Refer to HA-79.
I Keep friction surfaces between clutch and pulley clean. If the surface is contaminated with
lubricant, wipe it off by using a clean waste cloth moistened with thinner. PD
I After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour. AX
I After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.
SU
Precautions for Service Equipment NMHA0065 BR

RECOVERY/RECYCLING EQUIPMENT NMHA0065S01
Follow the manufacturer’s instructions for machine operation and
machine maintenance. Never introduce any refrigerant other than ST
that specified into the machine.
ELECTRONIC LEAK DETECTOR NMHA0065S02 RS
Follow the manufacturer’s instructions for tester operation and
tester maintenance.
BT
SC
EL
IDX
HA-7
PRECAUTIONS
Precautions for Service Equipment (Cont’d)
VACUUM PUMP NMHA0065S03
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric
pressure. So the vacuum pump lubricant may migrate out of the
pump into the service hose. This is possible when the pump is
switched off after evacuation (vacuuming) and hose is connected
to it.
To prevent this migration, use a manual valve situated near the
hose-to-pump connection, as follows.
I Usually vacuum pumps have a manual isolator valve as part
of the pump. Close this valve to isolate the service hose from
the pump.
I For pumps without an isolator, use a hose equipped with a
manual shut-off valve near the pump end. Close the valve to
isolate the hose from the pump.
I If the hose has an automatic shut off valve, disconnect the
hose from the pump: as long as the hose is connected, the
valve is open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
RHA270D
MANIFOLD GAUGE SET NMHA0065S04

Be certain that the gauge face indicates R-134a or 134a. Make
sure the gauge set has 1/2″-16 ACME threaded connections for
service hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) along with specified lubricant.
SHA533D
SERVICE HOSES NMHA0065S05

Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive
shut off devices (either manual or automatic) near the end of the
hoses opposite the manifold gauge.
RHA272D
SERVICE COUPLERS NMHA0065S06

Never attempt to connect HFC-134a (R-134a) service couplers to
an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
will not properly connect to the CFC-12 (R-12) system. However, if
an improper connection is attempted, discharging and contamina-
tion may occur.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
RHA273D
HA-8
PRECAUTIONS
Precautions for Service Equipment (Cont’d)
REFRIGERANT WEIGHT SCALE NMHA0065S07
Verify that no refrigerant other than HFC-134a (R-134a) and speci-
fied lubricants have been used with the scale. If the scale controls GI
refrigerant flow electronically, the hose fitting must be 1/2″-16
ACME.
MA
EM
RHA274D LC
CALIBRATING ACR4 WEIGHT SCALE NMHA0065S09
Calibrate the scale every three months. EC
To calibrate the weight scale on the ACR4:
1. Press Shift/Reset and Enter at the same time.
2. Press 8787. “A1” will be displayed. FE
3. Remove all weight from the scale.
4. Press 0, then press Enter. “0.00” will be displayed and change
to “A2”. CL
5. Place a known weight (dumbbell or similar weight), between
4.5 and 8.6 kg (10 and 19 lb) on the center of the weight scale. MT
6. Enter the known weight using four digits. (Example 10 lb =
10.00, 10.5 lb = 10.50)
7. Press Enter — the display returns to the vacuum mode. AT
8. Press Shift/Reset and Enter at the same time.
9. Press 6 — the known weight on the scale is displayed.
PD
10. Remove the known weight from the scale. “0.00” will be dis-
played.
11. Press Shift/Reset to return the ACR4 to the program mode. AX
SU
CHARGING CYLINDER NMHA0065S08

Using a charging cylinder is not recommended. Refrigerant may be
BR
vented into air from cylinder’s top valve when filling the cylinder
with refrigerant. Also, the accuracy of the cylinder is generally less ST
than that of an electronic scale or of quality recycle/recharge
equipment.
RS
BT
Wiring Diagrams and Trouble Diagnoses NMHA0066

When you read wiring diagrams, refer to the following:
I GI-11, “HOW TO READ WIRING DIAGRAMS”
SC
I EL-8, “Wiring Diagram — POWER —” for power distribution
circuit
When you perform trouble diagnoses, refer to the following: EL
I GI-31, “HOW TO FOLLOW TROUBLE DIAGNOSES”
I GI-20, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN
ELECTRICAL INCIDENT” IDX
HA-9
PREPARATION
Special Service Tools
Special Service Tools NMHA0273
Tool number
Description
Tool name
KV99231260 Removing shaft nut and clutch disc

Clutch disc wrench
NT204
KV992T0001 Removing clutch disc

Clutch disc puller
NT206
KV992T0002 Installing pulley

Pulley installer
NT207
KV99233130 Removing pulley

Pulley puller
NT208
HA-10
PREPARATION
HFC-134a (R-134a) Service Tools and Equipment
HFC-134a (R-134a) Service Tools and

Equipment =NMHA0068
Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubri-
GI
cant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/ MA
lubricant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid EM
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor failure will result. LC
Tool number
(Kent-Moore No.) Description
Tool name EC
HFC-134a (R-134a) Container color: Light blue
refrigerant Container marking: HFC-134a (R-134a) FE
Fitting size: Thread size
I Large container 1/2″-16 ACME
CL
NT196
KLH00-PAGR0 Type: Poly alkylene glycol oil (PAG), type R MT

Nissan A/C System Oil Application: HFC-134a (R-134a) swash plate (pis-
Type R ton) compressors (Nissan only)
Lubricity: 40 m (1.4 US fl oz, 1.4 Imp fl oz) AT
NT197
PD
Recovery/Recycling Function: Refrigerant Recovery and Recycling and
Recharging equipment Recharging
(ACR4) AX
SU
BR
NT195
Electrical leak detector Power supply:

I DC 12V (Cigarette lighter) ST
RS
BT
NT198
SC
EL
IDX
HA-11
PREPARATION
HFC-134a (R-134a) Service Tools and Equipment (Cont’d)
Tool number
Tool name
(J-43926) Power supply:

Refrigerant dye leak DC 12V (Battery terminal)
detection kit
Kit includes:
(J-42220) UV lamp and
UV safety glasses
(J-41459) Refrigerant
dye injector
(J-41447) qty. 24
R-134a refrigerant dye
(J-43872) Refrigerant
dye cleaner
SHA437F
(J-42220) UV lamp UV safety glasses Power supply: DC12V (Battery terminal)

Fluorescent dye leak For checking refrigerant leak when fluorescent dye
detector is installed in A/C system.
Includes: UV lamp and UV safety glasses
SHA438F
(J-41447) Dye Application: For R-134a PAG oil

R134a Fluorescent Leak Container: 1/4 ounce (7.4 cc) bottle
Detection Dye (Box of (Includes self-adhesive dye identification labels for
24, 1/4 ounce bottles) affixing to vehicle after charging system with dye.)
SHA439F
(J-41459) Dye injector For injecting 1/4 ounce of Fluorescent Leak Detec-
R134a Dye Injector tion Dye into A/C system.
Use with J-41447, 1/4
ounce bottle
SHA440F
(J-43872) For cleaning dye spills.

Dye cleaner
SHA441F
Manifold gauge set (with Identification:

hoses and couplers) I The gauge face indicates R-134a.
I 1/2″-16 ACME
NT199
HA-12
PREPARATION
HFC-134a (R-134a) Service Tools and Equipment (Cont’d)
Tool number
Tool name GI
Service hoses Hose color:
I High side hose I Low hose: Blue with black stripe MA
I Low side hose I High hose: Red with black stripe
I Utility hose I Utility hose: Yellow with black stripe or green
with black stripe
Hose fitting to gauge:
EM
I 1/2″-16 ACME
NT201
Service couplers Hose fitting to service hose:

LC
I High side coupler I M14 x 1.5 fitting is optional or permanently
I Low side coupler attached.
EC
NT202
FE
Refrigerant weight scale For measuring of refrigerant
Fitting size: Thread size CL
I 1/2″-16 ACME
MT
NT200 AT
Vacuum pump Capacity:
(Including the isolator I Air displacement: 4 CFM
valve) I Micron rating: 20 microns PD
I Oil capacity: 482 g (17 oz)
I 1/2″-16 ACME AX
NT203 SU
BR
ST
RS
BT
SC
EL
IDX
HA-13
DESCRIPTION
Refrigeration System
Refrigeration System
REFRIGERATION CYCLE NMHA0069
Refrigerant Flow NMHA0069S01
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the liquid tank,
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil
is controlled by an externally equalized expansion valve, located inside the evaporator case.
Refrigerant System Protection NMHA0069S03
Dual-pressure Switch NMHA0069S0303
The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch,
located on the liquid tank. If the system pressure rises above or falls below the specifications, the dual-pres-
sure switch opens to interrupt the compressor operation.
Fusible Plug NMHA0069S0304
Opens at temperatures above 105°C (221°F), thereby discharging refrigerant to the atmosphere. If this plug
is melted, check the refrigerant line and replace liquid tank.
ZHA086H
HA-14
DESCRIPTION
Component Layout
Component Layout NMHA0071
GI
MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
ZHA002H
BT
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IDX
HA-15
DESCRIPTION
Control Operation
Control Operation NMHA0072
ZHA003H
FAN CONTROL DIAL NMHA0072S01

This dial turns the fan ON and OFF, and controls fan speed.
MODE SWITCHES NMHA0072S02
This switch allows control of the outlet air flow.
In “DEF” or “D/F” mode, the intake door is set to “FRESH”.
The compressor turns on when the Mode switch is moved to “DEF”.
TEMPERATURE CONTROL LEVER NMHA0072S03
This lever allows adjustment of the temperature of the outlet air.
RECIRCULATION (REC) SWITCH NMHA0072S04
OFF position: Outside air is drawn into the passenger compartment.
ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light.
Recirculation is canceled when DEF or D/F is selected, and resumes when another mode is chosen.
If the refrigerant pressure sensor input signal is high, recirculation is canceled when VENT, B/L or FOOT mode
is selected.
AIR CONDITIONER SWITCH NMHA0072S05
The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the com-
pressor will turn ON. The indicator lamp will also light.
The air conditioner cooling function operates only when the engine is running.
HA-16
DESCRIPTION
Discharge Air Flow
Discharge Air Flow NMHA0073
GI
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EC
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CL
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AT
PD
AX
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EL
ZHA004H IDX
HA-17
DESCRIPTION
System Description
System Description NMHA0074

SWITCHES AND THEIR CONTROL FUNCTIONS NMHA0074S01
ZHA005H
ZHA006H
HA-18
TROUBLE DIAGNOSES
Component Location
Component Location NMHA0085

ENGINE COMPARTMENT NMHA0085S01
GI
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LC
EC
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EL
IDX
ZHA007H
HA-19
TROUBLE DIAGNOSES
Component Location (Cont’d)
PASSENGER COMPARTMENT NMHA0085S02
ZHA008H
HA-20
TROUBLE DIAGNOSES
Circuit Diagram — Air Conditioner
Circuit Diagram — Air Conditioner NMHA0087
GI
MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
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EL
THA284 IDX
HA-21
TROUBLE DIAGNOSES
Wiring Diagram — A/C, Heater —
Wiring Diagram — A/C, Heater — NMHA0265
THA285
HA-22
TROUBLE DIAGNOSES
Wiring Diagram — A/C, M —
Wiring Diagram — A/C, M — NMHA0088
GI
MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
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EL
THA286 IDX
HA-23
TROUBLE DIAGNOSES
Wiring Diagram — A/C, M — (Cont’d)
THA287
HA-24
TROUBLE DIAGNOSES
GI
MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
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ST
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EL
THA288
IDX
HA-25
TROUBLE DIAGNOSES
THA289
HA-26
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick and Accurate Repair
How to Perform Trouble Diagnoses for Quick

and Accurate Repair NMHA0075
GI
WORK FLOW NMHA0075S01
MA
EM
LC
SHA900E
EC
*1: HA-28 FE
SYMPTOM TABLE NMHA0075S02

CL
Symptom Reference page
I A/C system does not come on. I Go to Trouble Diagnosis Procedure for A/C system. HA-30 MT
I Intake door does not change in VENT, B/L or FOOT I Go to Trouble Diagnosis Procedure for Intake Door. HA-32
mode. AT
I Blower motor does not rotate at all. I Go to Trouble Diagnosis Procedure for Blower Motor. HA-36
I Insufficient cooling. I Go to Trouble Diagnosis Procedure for Insufficient HA-43 PD

cooling.
I Insufficient heating. I Go to Trouble Diagnosis Procedure for Insufficient HA-51

heating. AX
I Air mix door motor does not operate normally. I Go to Trouble Diagnosis Procedure for Air mix door HA-52
motor. SU
I Mode door does not change. I Go to Trouble Diagnosis Procedure for Mode door. HA-59
I Bi-level door motor does not operate normally. I Go to Trouble Diagnosis Procedure for Bi-level door. HA-62 BR
I Magnet clutch does not engage when A/C switch and I Go to Trouble Diagnosis Procedure for Magnet Clutch. HA-65
fan switch are ON.
ST
I Noise I Go to Trouble Diagnosis Procedure for Noise. HA-76
RS
BT
SC
EL
IDX
HA-27
TROUBLE DIAGNOSES
Operational Check
Operational Check =NMHA0076

The purpose of the operational check is to confirm that the system
operates as it should. The systems which are checked are the
blower, mode (discharge air), intake air, temperature decrease, and
temperature increase.
CONDITIONS: NMHA0076S01
Engine running at normal operating temperature.
PROCEDURE: NMHA0076S02
1. Check Blower NMHA0076S0201
1. Turn fan control dial to 1-speed.
Blower should operate on 1-speed.
2. Then turn fan control dial to 2-speed.
3. Continue checking blower speed until all four speeds are
checked.
4. Leave blower on 4-speed.
If NG, go to trouble diagnosis procedure for blower motor (HA-36).
If OK, continue with next check.
ZHA009H
2. Check Discharge Air NMHA0076S0202

1. Press each mode switch.
ZHA010H
2. Confirm that discharge air comes out according to the air dis-
tribution table at left.
Refer to “Discharge Air Flow” in “DESCRIPTION” (HA-17).
NOTE:
Confirm that the compressor clutch is engaged (visual inspection)
and intake door position is at FRESH when the DEF ( )
is pressed.
Confirm that the intake door position is at FRESH when the D/F
( ) is pressed.
Intake door position is checked in the next step.
If NG, go to trouble diagnosis procedure for mode door motor
(HA-59).
ZHA011H
HA-28
TROUBLE DIAGNOSES
Operational Check (Cont’d)
3. Check Recirculation NMHA0076S0203
1. Press recirculation switch.
Recirculation indicator should light. GI
2. Listen for intake door position change (you should hear blower
sound change slightly).
NOTE:
MA
Confirm that the RECIRCULATION (REC) switch is canceled in the
DEF ( ) and D/F ( ) modes. EM
If NG, go to trouble diagnosis procedure for intake door motor
(HA-32).
ZHA012H If OK, continue with next check. LC
4. Check Temperature Decrease NMHA0076S0204
1. Slide temperature control lever to full cold. EC
2. Check for cold air at discharge air outlets.
If NG, go to trouble diagnosis procedure for insufficient cooling
motor (HA-43). FE
CL
ZHA013H
MT
5. Check Temperature Increase NMHA0076S0205
1. Slide temperature control lever to full hot. AT
2. Check for hot air at discharge air outlets.
If NG, go to trouble diagnosis procedure for insufficient heating PD
motor (HA-51).
AX
SU
ZHA014H
6. Check Air Conditioner Switch NMHA0076S0206

Turn fan control switch to the desired (1 to 4-speed) position and
BR
push the air conditioner switch to turn ON the air conditioner.
The indicator light should come on when air conditioner is ON. ST
If NG, go to trouble diagnosis procedure for A/C system (HA-30).
If all operational checks are OK (symptom cannot be duplicated), RS
go to “Incident Simulation Tests” (GI-21) and perform tests as out-
lined to simulate driving conditions and environment. If symptom
appears, refer to “Symptom Table” (HA-27) and perform applicable BT
trouble diagnosis procedures.
ZHA015H
SC
EL
IDX
HA-29
TROUBLE DIAGNOSES
A/C System
A/C System
TROUBLE DIAGNOSIS PROCEDURE FOR A/C SYSTEM =NMHA0253
Symptom:
I A/C system does not come on.
INSPECTION FLOW
ZHA016H
*1: HA-31 *2: HA-28 *3: HA-21
HA-30
TROUBLE DIAGNOSES
A/C System (Cont’d)
MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK
=NMHA0254
Power Supply Circuit Check NMHA0254S01
Check power supply circuit for air conditioner system. GI
Refer to EL-8, “Wiring Diagram — POWER —”.
MA
EM
LC
DIAGNOSTIC PROCEDURE NMHA0255
SYMPTOM: EC
I A/C system does not come on.
1 CHECK POWER SUPPLY CIRCUIT FOR A/C CONTROL UNIT
FE
1. Disconnect A/C control unit harness connector.
2. Are there approx. 12 volts between each A/C control unit connector M31 terminal No. 2 (L/OR) and body ground?
CL
MT
AT
PD
ZHA017H
OK or NG AX
OK © GO TO 2.
NG © Check 10A fuse (No. 15) at fuse block. SU
2 CHECK BODY GROUND CIRCUIT FOR A/C CONTROL UNIT

BR
Check for continuity between A/C control unit harness connector M31 terminal No. 6 and body ground.
ST
RS
BT
ZHA019H
OK or NG
SC
OK © INSPECTION END
NG © If NG, repair harness or connector.
EL
IDX
HA-31
TROUBLE DIAGNOSES
Intake Door
Intake Door
TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR =NMHA0135
Symptom:
I Intake door does not change in VENT, B/L or FOOT mode.
Inspection Flow
ZHA021H
*1: HA-33 *2: HA-28 *3: HA-27
SYSTEM DESCRIPTION NMHA0136

Intake Door Motor NMHA0136S01
The intake door motor is installed on the blower unit. Using a link
it opens and closes the intake door.
When RECIRCULATION switch is at REC (except DEF and D/F
modes), the A/C control unit sets the intake door at the “RECIR-
CULATION” position.
RECIRCULATION switch is canceled by MODE switch in DEF and
D/F modes.
ZHA022H
HA-32
TROUBLE DIAGNOSES
Intake Door (Cont’d)
GI
MA
EM
ZHA023H LC
DIAGNOSTIC PROCEDURE NMHA0090
SYMPTOM: Intake door motor does not operate normally. EC
FE
CL
ZHA024H
MT
1 CHECK BODY GROUND CIRCUIT FOR INTAKE DOOR MOTOR
AT
1. Disconnect intake door harness connector.
2. Does continuity exist between intake door harness connector M48 terminal No. 5 (B) and body ground?
PD
AX
SU
BR
ST
RS
ZHA025H
BT
Yes or No
Yes © Reconnect intake door harness connector. GO TO 2.
No © Repair harness or connector.
SC
EL
IDX
HA-33
TROUBLE DIAGNOSES
2 CHECK FOR A/C CONTROL UNIT OUTPUT

Are there approx. 12 volts between each A/C control unit connector M32 terminals No. 15 (G/B), 23 (G/W) and body
ground.
ZHA026H
OK or NG
OK © Disconnect A/C control unit connector and intake door motor connector. GO TO 3.
NG © Replace A/C control unit.
HA-34
TROUBLE DIAGNOSES
3 CHECK CIRCUIT CONTINUITY BETWEEN A/C CONTROL UNIT AND INTAKE DOOR MOTOR
Check circuit continuity between each A/C control unit connector M32 terminal No. 15 (G/B), 16 (G), 23 (G/W) , 24 (W/B) GI
and intake door motor connector M48 terminal No. 1 (G), 4 (W/B), 6 (G/W), 7 (G/B).
MA
EM
LC
EC
FE
CL
MT
AT
PD
ZHA027H AX
Continuity should exist.
If OK, check harness for short.
OK or NG
SU
OK © Replace intake door motor.
NG © Repair harness or connector. BR
ST
RS
BT
CONTROL LINKAGE ADJUSTMENT NMHA0093

Intake Door Motor NMHA0093S04
1. Install intake door motor on blower and intake unit.
Ensure that the intake door motor lever is fitted into the slit SC
portion of intake door link.
2. Connect the intake door motor harness connector. EL
3. Turn ignition switch to ON.
4. Check that intake door operates properly when RECIRCULA-
TION switch is turned ON and OFF. IDX
ZHA023H
HA-35
TROUBLE DIAGNOSES
Blower Motor
Blower Motor
TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR =NMHA0138
Symptom:
I Blower motor does not rotate at all.
Inspection Flow
ZHA029H
*1: HA-38 *2: HA-28 *3: HA-27
HA-36
TROUBLE DIAGNOSES
Blower Motor (Cont’d)
ELECTRICAL COMPONENTS INSPECTION =NMHA0139
Fan Switch
Check continuity between terminals at each switch position.
NMHA0139S01
GI
SWITCH POSITION Continuity between terminals
OFF
MA
1 4—5—6
EM
2 3—5—6
3 2—5—6
ZHA030H LC
4 1—5—6
EC
FE
CL
MT
Blower Motor NMHA0139S02
Confirm smooth rotation of the blower motor. AT
I Ensure that there are no foreign particles inside the intake unit.
PD
AX
SU
Fan Resistor
Check resistance between terminals.
NMHA0139S03 BR
Terminal No.
Resistance ST
(+) (−)
2 Approx. 0.27 - 0.33Ω

RS
3 1 Approx. 0.855 - 1.045Ω
4 Approx. 2.25 - 2.75Ω

BT
ZHA031H
SC
EL
IDX
HA-37
TROUBLE DIAGNOSES
DIAGNOSTIC PROCEDURE =NMHA0089
SYMPTOM:
I Blower motor does not rotate.
Test group No. INCIDENT
1 Fan fails to rotate.
2 Fan does not rotate at 1-speed.
1 DIAGNOSTIC PROCEDURE
Check if blower motor rotates properly at each fan speed.
Conduct checks as per table above.
1 © GO TO 2.
2, 3, 4 © GO TO 8.
5 © GO TO 9.
HA-38
TROUBLE DIAGNOSES
2 CHECK POWER SUPPLY FOR BLOWER MOTOR

1. Disconnect blower motor harness connector. GI
2. Are there approx. 12 volts between blower motor harness connector M53 terminal No. 2 (L/W) and body ground?
MA
EM
LC
EC
FE
CL
ZHA032H
Yes or No MT
Yes © GO TO 3.
No © Check 15A (No. 19 and No. 24) fuses at fuse block. Refer to EL-11, “Wiring Diagram —
POWER —”.
AT
Check blower relay.
PD
3 CHECK CIRCUIT CONTINUITY FOR BLOWER MOTOR
1. Turn fan control switch to any position except OFF. AX
2. Check circuit continuity between blower motor harness connector M53 terminal No. 1 (L) and body ground.
SU
BR
ST
RS
BT
ZHA033H
If OK, check harness for short. SC
OK or NG
OK © GO TO 4. EL
NG © Reconnect blower motor harness connector. GO TO 5.
IDX
HA-39
TROUBLE DIAGNOSES
4 CHECK BLOWER MOTOR

(Refer to Electrical Components Inspection.)
(HA-37)
OK or NG
NG © Replace blower motor.
5 CHECK BLOWER MOTOR CIRCUIT BETWEEN BLOWER MOTOR AND RESISTOR

1. Disconnect resistor harness connector.
2. Are there approx. 12 volts between resistor harness connector M52 terminal No. 1 (L) and body ground?
ZHA034H
Yes or No
Yes © Disconnect fan switch harness connector. GO TO 7.
No © Disconnect blower motor and resistor harness connectors. GO TO 6.
HA-40
TROUBLE DIAGNOSES
6 CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND RESISTOR

Check circuit continuity between blower motor harness connector M53 terminal No. 1 (L) and resistor harness connector GI
M52 terminal No. 1 (L).
MA
EM
LC
EC
FE
CL
ZHA035H
If OK, check harness for short. MT
OK or NG
OK © GO TO 7. AT
NG © Repair harness or connector.
PD
7 CHECK GROUND CIRCUIT FOR FAN SWITCH
Check circuit continuity between fan switch harness connector M33 terminal No. 6 (R/B) and body ground. AX
SU
BR
ST
ZHA036H
RS
OK or NG
OK © GO TO 8.
BT
8 CHECK RESISTOR AFTER DISCONNECTING IT

(HA-37) SC
OK or NG
OK © Reconnect resistor harness connector. GO TO 9. EL
NG © Replace resistor.
IDX
HA-41
TROUBLE DIAGNOSES
9 CHECK FAN SWITCH CIRCUIT

Are there approx. 12 volts between each fan switch harness connector M33 terminal No. 1 (L), 2 (L/R), 3 (G/R), 4 (L/B)
and body ground?
ZHA037H
Yes or No
Yes © GO TO 11.
No © GO TO 10.
10 CHECK CIRCUIT CONTINUITY BETWEEN FAN SWITCH AND RESISTOR

Check circuit continuity between fan switch harness connector M33 terminal No. 1 (L), 2 (L/R), 3 (G/R), 4 (L/B) and resis-
tor harness connector M52 terminal No. 1 (L), 2 (L/R), 3 (G/R), 4 (L/B).
ZHA038H
OK or NG
OK © Check harness for short.
11 CHECK FAN SWITCH AFTER DISCONNECTING IT

(HA-37)
OK or NG
NG © Replace fan switch.
HA-42
TROUBLE DIAGNOSES
Insufficient Cooling
Insufficient Cooling
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING
Symptom:
=NMHA0150
GI
I Insufficient Cooling.
Inspection Flow MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
ZHA018H
SC
*1: HA-52 *4: HA-28 *7: HA-52
*2: HA-46 *5: HA-27 *8: MA-6
*3: HA-44 *6: HA-81 *9: EC-120 EL
IDX
HA-43
TROUBLE DIAGNOSES
Insufficient Cooling (Cont’d)
PERFORMANCE TEST DIAGNOSES NMHA0082
SHA419F
*1: HA-46 *3: HA-47 *4: HA-52

*2: HA-46
HA-44
TROUBLE DIAGNOSES
GI
MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
SHA334FB
SC
*7: HA-84 *8: HA-36 *9: EM-16
EL
IDX
HA-45
TROUBLE DIAGNOSES
PERFORMANCE TEST =NMHA0083
Test Condition NMHA0083S01
Testing must be performed as follows:
Vehicle location Indoors or in the shade (in a well-ventilated place)
Doors Closed
Door windows Open
Hood Open
TEMP. Max. COLD
Discharge Air Face Vent
REC switch (Recirculation) set
FAN speed High speed
Engine speed Idle speed
Operate the air conditioning system for 10 minutes before taking measurements.
Test Reading NMHA0083S02

Recirculating-to-discharge Air Temperature Table NMHA0083S0201
Inside air (Recirculating air) at blower assembly inlet

Discharge air temperature at center ventilator °C (°F)
Relative humidity % Air temperature °C (°F)
15 (59) 4.4 - 5.8 (40 - 42)
20 (68) 8.0 - 10.0 (46 - 50)

50 - 60
25 (77) 12.0 - 14.5 (54 - 58)
30 (86) 16.0 - 19.0 (61 - 66)
15 (59) 5.8 - 7.8 (42 - 46)
20 (68) 10.0 - 12.0 (50 - 54)

60 - 70
25 (77) 14.5 - 17.0 (58 - 63)
30 (86) 19.0 - 22.4 (66 - 72)
Ambient Air Temperature-to-operating Pressure Table NMHA0083S0202
Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Air temperature kPa (kg/cm2, psi) kPa (kg/cm2, psi)
Relative humidity %
°C (°F)
1,059 - 1,285 186 - 235

25 (77)
(10.8 - 13.1, 154 - 186) (1.9 - 2.4, 27 - 34)
1,206 - 1,471 216 - 275

30 (86)
(12.3 - 15.0, 175 - 213) (2.2 - 2.8, 31 - 40)
50 - 70
1,363 - 1,667 235 - 304
35 (95)
(13.9 - 17.0, 198 - 242) (2.4 - 3.1, 34 - 44)
1,520 - 1,854 294 - 363

40 (104)
(15.5 - 18.9, 220 - 269) (3.0 - 3.7, 43 - 53)
HA-46
TROUBLE DIAGNOSES
TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE =NMHA0084
Whenever the system’s high and/or low side pressure is abnormal, diagnose using a manifold gauge. The
marker above the gauge scale in the following tables indicates the standard (normal) pressure range. Since GI
the standard (normal) pressure, however, differs from vehicle to vehicle, refer to HA-46 (“Ambient air tempera-
ture-to-operating pressure table”).
MA
Both High and Low-pressure Sides are Too High. NMHA0084S01
Gauge indication Refrigerant cycle Probable cause Corrective action

EM
Both high and low-pressure sides I Pressure is reduced soon Excessive refrigerant charge Reduce refrigerant until speci-
are too high. after water is splashed on in refrigeration cycle fied pressure is obtained.
condenser. LC
Air suction by cooling fan is Insufficient condenser cooling I Clean condenser.
insufficient. performance I Check and repair cooling
" fan as necessary.
EC
1. Condenser fins are
clogged.
2. Improper fan rotation of FE
cooling fan
I Low-pressure pipe is not Poor heat exchange in con- Evacuate repeatedly and CL
cold. denser recharge system.
I When compressor is (After compressor operation
stopped, high-pressure stops, high pressure
AC359A value quickly drops by decreases too slowly.)
MT
approximately 196 kPa (2 "
kg/cm2, 28 psi). It then Air in refrigeration cycle
decreases gradually there- AT
after.
Engine tends to overheat. Engine cooling systems mal- Check and repair each PD
function. engine cooling system.
I An area of the low-pres- I Excessive liquid refrigerant Replace expansion valve.

sure pipe is colder than on low-pressure side AX
areas near the evaporator I Excessive refrigerant dis-
outlet. charge flow
I Plates are sometimes cov- I Expansion valve is open a SU
ered with frost. little compared with the
specification.
" BR
1. Improper thermal valve
installation
2. Improper expansion valve ST
adjustment
RS
BT
SC
EL
IDX
HA-47
TROUBLE DIAGNOSES
High-pressure Side is Too High and Low-pressure Side is Too Low. NMHA0084S02
High-pressure side is too high and Upper side of condenser and High-pressure tube or parts I Check and repair or
low-pressure side is too low. high-pressure side are hot, located between compressor replace malfunctioning
although liquid tank is not so and condenser are clogged or parts.
hot. crushed. I Check lubricant for con-
tamination.
AC360A
High-pressure Side is Too Low and Low-pressure Side is Too High. NMHA0084S03
High-pressure side is too low and High and low-pressure sides Compressor pressure opera- Replace compressor.
low-pressure side is too high. become equal soon after tion is improper.
compressor operation stops. "
Damaged inside compressor
packings
No temperature difference Compressor pressure opera- Replace compressor.

between high and low-pres- tion is improper.
sure sides "
Damaged inside compressor
packings.
AC356A
HA-48
TROUBLE DIAGNOSES
Both High- and Low-pressure Sides are Too Low. NMHA0084S04
Gauge indication Refrigerant cycle Probable cause Corrective action GI

Both high- and low-pressure sides I There is a big temperature Liquid tank is partly clogged. I Replace liquid tank.
are too low. difference between receiver I Check lubricant for con-
drier outlet and inlet. Outlet tamination. MA
temperature is extremely
low.
I Liquid tank inlet and EM
expansion valve are
frosted.
I Temperature of expansion High-pressure pipe located I Check and repair malfunc-

LC
valve inlet is extremely low between receiver drier and tioning parts.
compared with areas near expansion valve is clogged. I Check lubricant for con-
liquid tank. tamination. EC
I Expansion valve inlet may
be frosted.
AC353A
I Temperature difference FE
occurs somewhere in high-
pressure side
I Expansion valve and liquid Low refrigerant charge Check refrigerant for leaks.
CL
tank are warm or only cool " Refer to “Checking Refriger-
when touched. Leaking fittings or compo- ant Leaks”, HA-91.
nents MT
There is a big temperature Expansion valve closes a little I Remove foreign particles
difference between expansion compared with the specifica- by using compressed air. AT
valve inlet and outlet while tion. I Check lubricant for con-
the valve itself is frosted. " tamination.
1. Improper expansion valve
adjustment
PD
2. Malfunctioning thermal
valve
3. Outlet and inlet may be AX
clogged.
An area of the low-pressure Low-pressure pipe is clogged I Check and repair malfunc- SU
pipe is colder than areas near or crushed. tioning parts.
the evaporator outlet. I Check lubricant for con-
tamination.
BR
Air flow volume is not enough Evaporator is frozen. I Replace compressor.
or is too low. I Check thermo control amp.
operation. ST
Low-pressure Side Sometimes Becomes Negative. NMHA0084S05
RS
Low-pressure side sometimes I Air conditioning system Refrigerant does not dis- I Remove water from refrig-
becomes negative. does not function and does charge cyclically. erant or replace refrigerant.
BT
not cyclically cool the com- " I Replace liquid tank.
partment air. Moisture is frozen at expan-
I The system constantly sion valve outlet and inlet.
functions for a certain "
period of time after com- Water is mixed with refriger-
pressor is stopped and ant. SC
restarted.
EL
IDX
AC354A
HA-49
TROUBLE DIAGNOSES
Low-pressure Side Becomes Negative. NMHA0084S06
Low-pressure side becomes nega- Liquid tank or front/rear side High-pressure side is closed Leave the system at rest until
tive. of expansion valve’s pipe is and refrigerant does not flow. no frost is present. Start it
frosted or dewed. " again to check whether or not
Expansion valve or liquid tank the problem is caused by
is frosted. water or foreign particles.
I If water is the cause, ini-
tially cooling is okay. Then
the water freezes causing
a blockage. Remove water
from refrigerant or replace
refrigerant.
I If due to foreign particles,
remove expansion valve
and remove particles with
dry and compressed air
AC362A (not shop air).
I If either of the above meth-
ods cannot correct the
problem, replace expansion
valve.
I Replace liquid tank.
I Check lubricant for con-
tamination.
HA-50
TROUBLE DIAGNOSES
Insufficient Heating
Insufficient Heating
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING
Symptom:
=NMHA0140
GI
I Insufficient Heating.
Inspection Flow MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
ZHA039H
SC
*1: HA-52 *4: LC-15 *6: LC-13
*2: HA-28 *5: LC-11 *7: LC-16
*3: HA-27 EL
IDX
HA-51
TROUBLE DIAGNOSES
Air Mix Door
Air Mix Door

TROUBLE DIAGNOSIS PROCEDURE FOR AIR MIX DOOR MOTOR =NMHA0256
SYMPTOM:
I Air mix door motor does not operate normally.
INSPECTION FLOW
ZHA040H
*1: HA-58 *2: HA-54 *3: HA-28
HA-52
TROUBLE DIAGNOSES
Air Mix Door (Cont’d)
CONTROL SYSTEM INPUT COMPONENT NMHA0258
PBR NMHA0258S01
Measure resistance between connector M27 terminal No. 2 and 3 GI
at vehicle harness side.
MA
EM
ZHA042H LC
EC
FE
CL
ZHA041H
MT
PTC NMHA0258S02
Check resistance between connector M35 terminal No. 21 and + AT
at each lever position.
Terminal No. Lever position Resistance PD
Full cold Approx. 0 kΩ
+ 21
Full hot Approx. 1 kΩ AX
SU
ZHA020H
BR
ST
RS
BT
SC
EL
IDX
HA-53
TROUBLE DIAGNOSES
SYMPTOM:
I Air mix door motor does not operate normally.
1 CHECK POWER SUPPLY FOR A/C CONTROL UNIT
Refer to “MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK”, HA-31.
OK or NG
OK © GO TO 2.
NG © Repair or replace.
2 CHECK PBR
Refer to HA-53.
OK or NG
OK © GO TO 3.
NG © Replace air mix door motor.
3 CHECK PTC
Refer to HA-53.
OK or NG
OK © GO TO 4.
NG © Replace PTC.
4 CHECK POWER SUPPLY FOR PTC.

Are there approx. 12 volts between PTC harness connector M35 terminal No. + (L/OR) and body ground?
ZHA089H
Yes or No
Yes © Disconnect PTC connector. GO TO 5.
No © Check 10A (No. 19) fuse at fuse block. Refer to EL-8, “Wiring Diagram — POWER
—”.
HA-54
TROUBLE DIAGNOSES
5 CHECK GROUND CIRCUIT FOR PTC.

Check circuit continuity between PTC harness connector M35 terminal No. G (B) and body ground. GI
MA
EM
LC
EC
FE
ZHA090H CL
OK or NG
OK © Disconnect A/C control unit connector. GO TO 6. MT
AT
6 CHECK CIRCUIT CONTINUITY BETWEEN AIR MIX DOOR MOTOR AND A/C CONTROL UNIT
Check circuit continuity between PTC harness connector M35 terminal No. 21 (W/L), + (L/OR) and A/C control unit har- PD
ness connector M31 terminal No. 2 (L/OR), M32 terminal No. 21 (W/L).
AX
SU
BR
ST
RS
BT
ZHA091H
OK or NG
OK © GO TO 7. SC
EL
IDX
HA-55
TROUBLE DIAGNOSES
7 CHECK FOR OUTPUT OF AUTO AMP.

Are there approx. 12 volts between air mix door motor harness connector M27 terminal No. 4 (R), 5 (R/W) and body
ground?
ZHA069H
Yes or No
Yes © GO TO 8.
No © Replace A/C control unit.
8 CHECK POWER SUPPLY FOR PBR.

Are there approx. 12 volts between air mix door motor harness connector M75 terminal No. 3 (L/OR) and body ground?
ZHA043H
Yes or No
Yes © Disconnect air mix door motor connector. GO TO 9.
No © Check 10A (No. 19) fuse at fuse block. Refer to EL-8, “Wiring Diagram — POWER
—”.
HA-56
TROUBLE DIAGNOSES
9 CHECK GROUND CIRCUIT FOR PBR.

Check circuit continuity between air mix door motor harness connector M27 terminal No. 1 (B) and body ground. GI
MA
EM
LC
EC
FE
ZHA044H CL
OK or NG
OK © Disconnect A/C control unit connector. GO TO 10. MT
AT
10 CHECK CIRCUIT CONTINUITY BETWEEN AIR MIX DOOR MOTOR AND A/C CONTROL UNIT
Check circuit continuity between air mix door motor harness connector M27 terminal No. 4 (R), 5 (L/W) and A/C control PD
unit harness connector M32 terminal No. 14 (R/W), 22 (R).
AX
SU
BR
ST
RS
BT
ZHA045H
If OK, check harness for short. SC
OK or NG
OK © Replace air mix door motor. EL
IDX
HA-57
TROUBLE DIAGNOSES
Air Mix Door NMHA0257S01
Push air mix door lever in direction of arrow and attach air mix door
to rod holder.
1. Install air mix door motor on heater unit and connect it to main
harness.
Make sure lever of air mix door is fitted into the slit of the air
mix door link.
3. Slide temperature control lever to full cold.
ZHA046H
4. Move air mix door by hand to maximum cold position and hold
it.
5. While holding air mix door, adjust length of temperature con-
trol rod and connect it to air mix door lever.
6. Check that air mix door operates properly when temperature
control lever is slid to full hot and full cold.
HA-58
TROUBLE DIAGNOSES
Mode Door
Mode Door
TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR
Symptom:
=NMHA0142
GI
I Air outlet does not change.
Inspection Flow MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
ZHA047H
SC
*1: HA-61 *3: HA-27 *5: HA-60
*2: HA-28 *4: HA-17
EL
IDX
HA-59
TROUBLE DIAGNOSES
Mode Door (Cont’d)
SYMPTOM:
I Mode door motor does not operate normally.
Refer to “MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK”, HA-31.
OK or NG
OK © GO TO 2.
2 CHECK FOR OUTPUT OF A/C CONTROL UNIT

Are there approx. 12 volts between mode door motor harness connector M28 terminal No. 7 (G/OR), 8 (G/Y) and body
ground?
ZHA048H
Yes or No
Yes © Disconnect mode door motor and A/C control unit connector. GO TO 4.
No © Disconnect mode door motor and A/C control unit connector. GO TO 3.
3 CHECK CIRCUIT CONTINUITY BETWEEN MODE DOOR MOTOR AND A/C CONTROL UNIT
Check circuit continuity between mode door motor harness connector M28 terminal No. 7 (G/OR), 8 (G/Y) and A/C control
unit harness connector M32 terminal No. 17 (G/Y), 25 (G/OR).
ZHA049H
OK or NG
OK © Replace A/C control unit.
HA-60
TROUBLE DIAGNOSES
Mode Door (Cont’d)
4 CHECK CIRCUIT CONTINUITY BETWEEN MODE DOOR MOTOR AND A/C CONTROL UNIT
Check circuit continuity between mode door motor harness connector M28 terminal No. 1 (B/W), 2 (R/G), 3 (L/R), 4 (L/W), GI
5 (L/B), 6 (L) and A/C control unit harness connector M32 terminal No. 18 (R/G), 19 (L/W), 20 (L), 26 (B/W), 27 (L/R), 28
(L/B).
MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
ZHA050H
If OK, check harness for short. SU
OK or NG
OK © Replace air mix door motor. BR
ST
RS
BT

Mode Door NMHA0151S01
1. Install mode door motor on heater unit and connect it to main
harness. SC
Make sure lever of mode door motor is fitted into the slit of
mode door link.
EL
3. Turn VENT switch ON.
4. Turn DEF switch ON. Check that slide link operates at the full- IDX
open position. Also turn DEF switch ON to check that slide link
ZHA051H operates at the fully-open position.
HA-61
TROUBLE DIAGNOSES
Bi-Level Door
Bi-Level Door
TROUBLE DIAGNOSIS PROCEDURE FOR BI-LEVEL DOOR =NMHA0274
Symptom:
I Bi-level door motor does not operate normally.
Inspection Flow
ZHA052H
*1: HA-64 *3: HA-27 *5: HA-63

*2: HA-28 *4: HA-17
HA-62
TROUBLE DIAGNOSES
Bi-Level Door (Cont’d)
SYMPTOM:
I Bi-level door motor does not operate normally. GI
Refer to “MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK”, HA-31. MA
OK or NG
OK © GO TO 2. EM
LC
2 CHECK FOR OUTPUT OF A/C CONTROL UNIT
Are there approx. 12 volts between bi-level door motor harness connector M29 terminal No.1 (R/B), 2 (R/Y) and body EC
ground.
FE
CL
MT
ZHA053H
AT
OK or NG
OK © Disconnect bi-level door motor connector. GO TO 3. PD
NG © Replace auto amp.
AX
3 CHECK CIRCUIT CONTINUITY BETWEEN BI-LEVEL DOOR AND A/C CONTROL UNIT
Check circuit continuity between bi-level door motor harness connector M29 terminal No. 1 (R/B), 2 (R/Y) and A/C control SU
unit harness connector M31 terminal No. 11 (R/Y), 12 (R/B).
BR
ST
RS
BT
ZHA054H
OK or NG
OK © Replace bi-level door motor.
SC
NG © Replace harness or connector.
EL
IDX
HA-63
TROUBLE DIAGNOSES
Bi-Level Door (Cont’d)
Bi-Level Door NMHA0278S01
1. Install bi-level door motor on heater unit and connector it to
main harness.
Make sure lever of bi-level door motor is fitted into the slit of
bi-level door link.
3. Turn vent switch ON.
4. Turn BI-LEVEL switch ON. Check that slide link operates at the
full open position.
ZHA055H Also turn BI-LEVEL switch ON to check that slide link operates
at the fully-open position.
HA-64
TROUBLE DIAGNOSES
Magnet Clutch
Magnet Clutch
TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH
Symptom:
=NMHA0119
GI
I Magnet clutch does not operate when A/C switch and fan switch are ON.
Inspection Flow MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
ZHA056H
SC
*1: HA-91 *3: HA-28 *5: EM-16
*2: HA-66 *4: HA-27
EL
IDX
HA-65
TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
SYMPTOM:
I Magnet clutch does not engage when A/C switch and fan
switch are ON.
1 CHECK POWER SUPPLY FOR COMPRESSOR
1. Disconnect compressor harness connector.
2. Are there approx. 12 volts between compressor harness connector F21 terminal No. 1 (L/R) and body ground?
ZHA057H
Yes or No
Yes © GO TO 2.
No © Disconnect A/C relay. GO TO 3.
2 CHECK MAGNET CLUTCH COIL
OK or NG
OK © Refer to STEP 6 in HA-65.
NG © Replace magnet clutch. Refer to HA-82.
HA-66
TROUBLE DIAGNOSES
3 CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND COMPRESSOR

Check circuit continuity between A/C relay harness connector E5 terminal No. 3 (L/R) and compressor harness connector GI
F21 terminal No. 1 (L/R).
MA
EM
LC
EC
FE
CL
ZHA058H
If OK, check harness for short. MT
OK or NG
OK © GO TO 4. AT
PD
4 CHECK POWER SUPPLY FOR A/C RELAY
Disconnect A/C relay. AX
Are there approx. 12 volts between A/C relay harness connector E5 terminal No. 2 (L/OR), 5 (G/B) and body ground?
SU
BR
ST
RS
BT
ZHA059H
Yes or No SC
Yes © GO TO 5.
No © Check power supply circuit and 10A (No. 19, 66) fuse at fuse block. Refer to EL-8,
“Wiring Diagram — POWER —”.
EL
IDX
HA-67
TROUBLE DIAGNOSES
5 CHECK A/C RELAY AFTER DISCONNECTING IT

Refer to HA-75.
OK or NG
OK © Reconnect A/C relay. GO TO 6.
NG © Replace A/C relay.
6 CHECK COIL SIDE CIRCUIT OF A/C RELAY

Are there approx. 12 volts between ECM harness connector F1 terminal No. 11 (G) and body ground?
ZHA060H
Yes or No
Yes © GO TO 8.
No © Disconnect A/C relay. Disconnect ECM harness connector. GO TO 7.
HA-68
TROUBLE DIAGNOSES
7 CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND ECM

Check circuit continuity between A/C relay harness connector E5 terminal No. 1 (G) and ECM harness connector F1 termi- GI
nal No. 11 (G).
MA
EM
LC
EC
FE
CL
ZHA061H
MT
OK or NG
OK © Check harness for short.
AT
8 CHECK VOLTAGE FOR ECM PD

Are there approx. 12 volts between ECM harness connector F1 terminal No. 41 (L/B) and body ground?
AX
SU
BR
ST
RS
BT
ZHA062H
Yes or No
Yes © GO TO 9.
SC
No © Check ECM. Refer to EC-76, “Description”.
Repair harness or connector.
EL
IDX
HA-69
TROUBLE DIAGNOSES
9 CHECK POWER SUPPLY FOR THERMO CONTROL AMP.

Are there approx. 12 volts between thermo control amp. harness connector M49 terminal No. 1 (L/OR) and body ground?
ZHA063H
Yes or No
Yes © GO TO 10.
No © Check power supply circuit and 10A (No. 15) fuse at fuse block. Refer to EL-11, “Igni-
tion Power Supply — Ignition SW. in “ON”.
I If OK, check for open circuit in wiring harness.
Repair or replace as necessary.
I If NG, replace fuse and check wiring harness for short circuit.
Repair or replace as necessary.
HA-70
TROUBLE DIAGNOSES
10 CHECK POWER SUPPLY FOR THERMO CONTROL AMP.

Are there approx. 12 volts between thermo control amp. harness connector M49 terminal No. 3 (R) and body ground? GI
MA
EM
LC
EC
FE
CL
ZHA064H MT
Yes or No
Yes © GO TO 11. AT
No © Repair or replace thermo control amp.
PD
11 CHECK THERMO CONTROL AMP. OPERATION
Does magnet clutch engage when there is a short-circuit between thermo control amp. harness connector M49 terminal
No. 2 and body ground? AX
SU
BR
ST
RS
BT
ZHA065H
SC
Yes or No
Yes © GO TO 12. EL
No © GO TO 13.
IDX
HA-71
TROUBLE DIAGNOSES
12 CHECK THERMO CONTROL AMP.

Refer to “Thermo Control Amp.”, HA-74.
OK or NG
OK © GO TO 13.
NG © Replace thermo control amp.
13 CHECK CIRCUIT CONTINUITY BETWEEN THERMO CONTROL AMP. AND A/C SWITCH
Disconnect A/C switch harness connector.
Check circuit continuity between thermo control amp. harness connector M49 terminal No. 2 (LG/B) and A/C switch har-
ness connector M34 terminal No. 3 (LG/B).
ZHA066H
OK or NG
OK © GO TO 14.
HA-72
TROUBLE DIAGNOSES
14 CHECK CIRCUIT CONTINUITY BETWEEN FAN SWITCH AND A/C SWITCH

Check circuit continuity between fan switch harness connector M33 terminal No. 5 (LG/R) and A/C switch harness connec- GI
tor M34 terminal No. 4 (LG/R).
MA
EM
LC
EC
FE
CL
ZHA067H
MT
OK or NG
OK © GO TO 15.
AT
15 CHECK BODY GROUND CIRCUIT FOR FAN SWITCH PD

Does continuity exist between fan switch harness terminal No. 6 (R/B) and body ground?
AX
SU
BR
ST
RS
BT
ZHA068H
Yes or No
Yes © GO TO 16.
SC
No © Repair harness or connector.
EL
IDX
HA-73
TROUBLE DIAGNOSES
16 CHECK FAN SWITCH

Refer to HA-37.
OK or NG
OK © Replace A/C control unit.
NG © Replace fan switch.
ELECTRICAL COMPONENTS INSPECTION NMHA0279

Thermo Control Amp. NMHA0279S01
1. Run engine, and operate A/C system.
2. Connect the voltmeter from harness side.
3. Check thermo control amp. operation shown in the table.
Evaporator outlet air tempera-
Thermo amp. opera-
ture Tester
tion
°C (°F)
Decreasing to 2.5 - 3.5 (37 -

Turn OFF Approx. 12V
ZHA070H 38)
Increasing to 4.0 - 5.0 (39 -

Turn ON Approx. 0V
41)
ZHA092H
Thermal Protector NMHA0279S02
Temperature of compressor
Operation
°C (°F)
Increasing to approx. 140 - 150 (284 - 302) Turn OFF
Decreasing to approx. 125 - 135 (257 - 275) Turn ON
If NG, replace thermal protector.
ZHA071H
HA-74
TROUBLE DIAGNOSES
Dual-pressure Switch =NMHA0279S03
High-pressure side line GI

Terminals pressure Operation Continuity
kPa (kg/cm2, psi)
Increasing to MA
157 - 216 ON Exists.
Low-pres- (1.6 - 2.2, 23 - 31)
sure side
1-2
Decreasing to
EM
Does not
152.0 - 201.0 OFF
exist.
(1.55 - 2.05, 22.0 - 29.2)
ZHA072H LC
Decreasing to
1,373 - 1,765 ON Exists
High-pres- (14 - 18, 199 - 256) EC
1-2
sure side Increasing to
Does not
2,648 - 2,844 OFF
(27 - 29, 384 - 412)
exist. FE
CL
MT
A/C Relay NMHA0279S04
Check continuity between terminal Nos. 3 and 5. AT
Conditions Continuity
12V direct current supply between terminal Nos. 1 PD

Yes
and 2
No current supply No AX
If NG, replace relay.
SU
SHA471F
BR
ST
RS
BT
SC
EL
IDX
HA-75
TROUBLE DIAGNOSES
Noise
Noise
TROUBLE DIAGNOSIS PROCEDURE FOR NOISE =NMHA0080
Symptom:
I Noise
Inspection Flow
SHA336FA
*1: HA-82 *3: HA-79 *4: EM-16

*2: HA-84
HA-76
SERVICE PROCEDURE
HFC-134a (R-134a) Service Procedure
HFC-134a (R-134a) Service Procedure NMHA0094

SETTING OF SERVICE TOOLS AND EQUIPMENT NMHA0094S01
GI
Discharging Refrigerant NMHA0094S0101
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and MA
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant.
If accidental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers. EM
LC
EC
FE
CL
MT
AT
SHA539DE PD
Evacuating System and Charging Refrigerant NMHA0094S0102

AX
SU
BR
ST
RS
BT
SHA540DC
SC
EL
IDX
HA-77
SERVICE PROCEDURE
HFC-134a (R-134a) Service Procedure (Cont’d)
SHA386FA
*1: HA-79 *3: HA-92 *4: HA-44

*2: HA-91
HA-78
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor
Maintenance of Lubricant Quantity in

Compressor
The lubricant in the compressor circulates through the system with
NMHA0095
GI
the refrigerant. Add lubricant to compressor when replacing any
component or after a large gas leakage. It is important to maintain MA
the specified amount. If lubricant quantity is not maintained
properly, the following malfunctions may result:
I Lack of lubricant: May lead to a seized compressor EM
I Excessive lubricant: Inadequate cooling (thermal exchange
interference)
LC
LUBRICANT NMHA0095S01
Name: Nissan A/C System Oil Type R
Part number: KLH00-PAGR0 EC
CHECKING AND ADJUSTING NMHA0095S02
Adjust the lubricant quantity according to the test group shown FE
below.
1 LUBRICANT RETURN OPERATION
CL
Can lubricant return operation be performed?
I A/C system works properly.
I There is no evidence of a large amount of lubricant leakage. MT
Yes or No
Yes © GO TO 2.
AT
No © GO TO 3.
PD
2 PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS
1. Start engine, and set the following conditions:
Test condition AX
Engine speed: Idling to 1,200 rpm
A/C or AUTO switch: ON
Blower speed: Max. position SU
Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).]
2. Perform lubricant return operation for about 10 minutes.
3. Stop engine. BR
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
ST
© GO TO 3.
RS
3 CHECK COMPRESSOR
Should the compressor be replaced?
BT
Yes or No
Yes © GO TO HA-80.
No © GO TO 4.
SC
4 CHECK ANY PART
Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of
lubricant leakage.) EL
Yes or No
Yes © GO TO HA-80. IDX
No © Carry out the A/C performance test.
HA-79
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor (Cont’d)
Lubricant Adjusting Procedure for Components
Replacement Except Compressor NMHA0095S0201
After replacing any of the following major components, add the
correct amount of lubricant to the system.
Amount of lubricant to be added
Lubricant to be added to
system
Part replaced Remarks
Amount of lubricant
m (US fl oz, Imp fl oz)
Evaporator 75 (2.5, 2.6) —
Condenser 35 (1.2, 1.2) —
Add if compressor is not

Liquid tank 10 (0.3, 0.4)
replaced. *1
In case of refrigerant 30 (1.0, 1.1) Large leak

leak — Small leak *2
*1: If compressor is replaced, addition of lubricant is included in the table.

*2: If refrigerant leak is small, no addition of lubricant is needed.
Lubricant Adjustment Procedure for Compressor

Replacement NMHA0095S0202
1. Discharge refrigerant into the refrigerant recovery/recycling
equipment. Measure lubricant discharged into the recovery/
recycling equipment.
2. Drain the lubricant from the “old” (removed) compressor into a
graduated container and recover the amount of lubricant
drained.
3. Drain the lubricant from the “new” compressor into a separate,
clean container.
4. Measure an amount of new lubricant installed equal to amount
drained from “old” compressor. Add this lubricant to “new” com-
pressor through the suction port opening.
5. Measure an amount of new lubricant equal to the amount
recovered during discharging. Add this lubricant to “new” com-
pressor through the suction port opening.
6. If the liquid tank also needs to be replaced, add an additional
5 m (0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 m (0.2 Imp fl oz) of lubricant if only replac-
ing the compressor.
HA-80
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
PD
RHA065DJ
AX
SU
Compressor BR
REMOVAL AND INSTALLATION NMHA0287
ST
RS
BT
SC
EL
IDX
ZHA073H
HA-81
SERVICE PROCEDURE
Compressor Clutch — DKV-11G (ZEXEL make)
Compressor Clutch — DKV-11G (ZEXEL make)

OVERHAUL NMHA0280
RHA668H
REMOVAL NMHA0281
I Remove the two screws holding the connector bracket, ther-
mal protector to the compressor.
RHA669H
I When removing center bolt, hold clutch disc with clutch disc
wrench.
SHA097EA
I Remove the drive plate using the clutch disc puller.

Insert holder’s three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate. Tighten the center bolt to
remove the drive plate.
While tightening the center bolt, insert a screwdriver between
two of the pins (as shown in the figure) to prevent rotation.
After removing the drive plate, remove the shims from either
the drive shaft or the drive plate.
ZHA093H
HA-82
SERVICE PROCEDURE
Compressor Clutch — DKV-11G (ZEXEL make) (Cont’d)
I Remove the snap ring using external snap ring pliers.
GI
MA
EM
RHA072C LC
I Pulley removal:
Use a commercially available pulley puller. Position the center
of the puller on the end of the drive shaft. Remove the pulley EC
assembly with the puller.
For pressed pulleys:
To prevent deformation of the pulley groove, the puller FE
claws should be hooked under (not into) the pulley
groove.
For machine latched pulleys: CL
Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.
MT
SHA099EA
I Remove the snap ring using external snap ring pliers.
I Remove the field coil harness clip using a screwdriver. Then
remove the three field coil fixing screws and remove the field AT
coil.
PD
AX
SU
RHA074C
INSPECTION NMHA0282 BR
Clutch Disc NMHA0282S01
If the contact surface shows signs of damage due to excessive
heat, replace clutch disc and pulley. ST
Pulley NMHA0282S02
Check the appearance of the pulley assembly. If contact surface of RS
pulley shows signs of excessive grooving, replace clutch disc and
pulley. The contact surfaces of the pulley assembly should be
cleaned with a suitable solvent before reinstallation. BT
RHA075C Coil NMHA0282S03
Check coil for loose connection or cracked insulation.
SC
EL
IDX
HA-83
SERVICE PROCEDURE
INSTALLATION NMHA0283
I Install the field coil.
Be sure to align the coil pin with the hole in the compres-
sor front head.
I Install the field coil harness clip using a screwdriver.
RHA076C
I Install the pulley assembly using the installer and a hand

press, and then install the snap ring using snap ring pliers.
ZHA094H
I Install the drive plate on the drive shaft, together with the
original shim(s). Press the drive plate down by hand.
RHA078C
I Using the holder to prevent drive plate rotation, tighten the bolt
to 12 to 15 N·m (1.2 to 1.5 kg-m, 9 to 11 ft-lb) torque.
I After tightening the bolt, check that the pulley rotates
smoothly.
SHA101EA
HA-84
SERVICE PROCEDURE
I Check clearance all the way around the clutch disc.
Disc-to-pulley clearance:
0.3 - 0.6 mm (0.012 - 0.024 in) GI
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
MA
EM
LC
EC
FE
CL
RHA080C
MT
Break-in Operation NMHA0283S01
When replacing compressor clutch assembly, always conduct the AT
break-in operation. This is done by engaging and disengaging the
clutch about thirty times. Break-in operation raises the level of
transmitted torque. PD
AX
SU
Thermal Protector BR
INSPECTION NMHA0284
I When servicing, do not allow foreign matter to enter compres-
sor. ST
I Check continuity between compressor harness terminal and
field coil.
RS
BT
RHA671H
SC
EL
IDX
HA-85
SERVICE PROCEDURE
Heater Unit (Heater Core)
Heater Unit (Heater Core)

REMOVAL NMHA0261
ZHA085H
ZHA095H
1. Drain the cooling system. Refer to LC-15, “Changing Engine

Coolant”.
2. Discharge the A/C system. Refer to HA-77.
3. Disconnect the two heater hoses from inside the engine com-
partment.
4. Remove the instrument panel assembly. Refer to BT-22,
“Removal and Installation”.
HA-86
SERVICE PROCEDURE
Heater Unit (Heater Core) (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
ZHA096H
PD
5. Remove the cooling unit. Refer to HA-89.
6. Remove the steering member.
AX
SU
7. Remove the heater unit.
8. Remove the heater core.
BR
INSTALLATION
Installation is basically the reverse order of removal.
NMHA0262
ST
When filling radiator with coolant, refer to LC-15, “Changing
Engine Coolant”.
Recharge the A/C system. Refer to HA-77. RS
BT
ZHA097H
SC
EL
IDX
HA-87
SERVICE PROCEDURE
Blower Unit
Blower Unit
REMOVAL NMHA0288
ZHA074H
1. Discharge the A/C system. Refer to “Discharging Refrigerant”,

HA-77.
2. Disconnect the two refrigerant lines from the engine compart-
ment.
Cap the A/C lines to prevent moisture from entering the sys-
tem.
3. Remove cooling unit. Refer to “REMOVAL”, HA-89.
4. Move ECM unit to a position where it cannot be damaged dur-
ing blower unit removal and installation.
5. Disconnect the resistor and blower motor connector.
ZHA075H 6. Remove blower unit.
7. Remove the three bolts and then remove the motor from the
blower case.
Install in the reverse order of removal.
Recharge the A/C system. Refer to “Evacuating System and
Charging Refrigerant”, HA-77.
ZHA076H
HA-88
SERVICE PROCEDURE
Cooling Unit (A/C Evaporator)
Cooling Unit (A/C Evaporator)

REMOVAL NMHA0263
GI
MA
EM
LC
EC
FE
CL
ZHA077H
MT
1. Discharge the A/C system. Refer to HA-77.
2. Disconnect the two refrigerant lines from the engine compart- AT
ment.
Cap the A/C lines to prevent moisture from entering the sys-
tem. PD
3. Remove the glove box and mating trim. Refer to BT-22,
“Removal and Installation”.
4. Remove the instrument panel reinforcement. AX
5. Cut the instrument lower center panel along the guide lines.
6. Disconnect the thermal amp. connector. SU
ZHA078H 7. Remove the cooling unit.
8. Separate the cooling unit case, and remove the evaporator.
BR
Installation is basically the reverse order of removal.
Recharge the A/C system. Refer to HA-77. ST
RS
BT
ZHA079H
SC
EL
IDX
ZHA080H
HA-89
SERVICE PROCEDURE
Refrigerant Lines
Refrigerant Lines
REMOVAL AND INSTALLATION =NMHA0101
I Refer to page HA-4 regarding “Precautions for Refrigerant Connection”.
ZHA081H
HA-90
SERVICE PROCEDURE
Refrigerant Lines (Cont’d)
CHECKING FOR REFRIGERANT LEAKS =NMHA0292
Preliminary Check
I
NMHA0292S04
Perform a visual inspection of all refrigeration parts, fittings, GI
hoses and components for signs of A/C lubricant leakage,
damage and corrosion. A/C lubricant leakage may indicate an
area of refrigerant leakage. Allow extra inspection time in these MA
areas when using either an electronic refrigerant leak detector
or fluorescent dye leak detector.
EM
I If dye is observed, confirm the leak with an electronic refriger-
ant leak detector. It is possible a prior leak was repaired and
not properly cleaned. LC
I When searching for leaks, do not stop when one leak is found
but continue to check for additional leaks at all system compo-
nents and connections. EC
I When searching for refrigerant leaks using an electronic leak
detector, move the probe along the suspected leak area at 25
to 50 mm (1 to 2 in) per second and no further than 1/4 inch FE
from the component.
NOTE:
Moving the electronic leak detector probe slower and closer to
CL
the suspected leak area will improve the chances of finding a
leak. MT
ELECTRONIC REFRIGERANT LEAK DETECTOR NMHA0293
Precautions for Handling Leak Detector NMHA0293S01
AT
When performing a refrigerant leak check, use an A/C leak detec-
tor or equivalent. Ensure that the instrument is calibrated and set
properly per the operating instructions. PD
The leak detector is a delicate device. In order to use the leak
detector properly, read the operating instructions and perform any
specified maintenance. AX
I Other gases in the work area or substances on the A/C
components, for example, anti-freeze, windshield washer SU
SHA705EB fluid, solvents and lubricants, may falsely trigger the leak
detector. Make sure the surfaces to be checked are clean.
Clean with a dry cloth or blow off with shop air. BR
I Do not allow the sensor tip of the detector to contact with
any substance. This can also cause false readings and
may damage the detector. ST
RS
BT
1. Position probe approximately 5 mm (3/16 in) away from point

to be checked.
SC
EL
IDX
SHA707EA
HA-91
SERVICE PROCEDURE
2. When testing, circle each fitting completely with probe.
SHA706E
3. Move probe along component approximately 25 to 50 mm (1

to 2 in)/sec.
SHA708EA
Checking Procedure NMHA0293S02

To prevent inaccurate or false readings, make sure there is no
refrigerant vapor, shop chemicals, or cigarette smoke in the
vicinity of the vehicle. Perform the leak test in a calm area (low
air/wind movement) so that the leaking refrigerant is not dis-
persed.
1. Turn engine off.
2. Connect a suitable A/C manifold gauge set to the A/C service
ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45
bar, 3.52 kg/cm2, 50 psi) above 16°C (61°F). If less than
specification, recover/evacuate and recharge the system with
the specified amount of refrigerant.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected
since the system may not reach 345 kPa (3.45 bar, 3.52 kg/cm2,
50 psi).
4. Conduct the leak test from the high side (compressor dis-
charge a to evaporator inlet f) to the low side (evaporator drain
hole g to shaft seal k). Refer to HA-90. Perform a leak check
for the following areas carefully. Clean the component to be
checked and move the leak detector probe completely around
the connection/component.
I Compressor
Check the fittings of high and low pressure hoses and the shaft
seal.
I Liquid tank
Check the pressure switch, tube fitting, weld seams and the
fusible plug mount.
I Service valves
Check all around the service valves. Ensure service valve caps
are secured on the service valves (to prevent leaks).
HA-92
SERVICE PROCEDURE
NOTE:
After removing A/C manifold gauge set from service valves, wipe
any residue from valves to prevent any false readings by leak GI
detector.
I Cooling unit (Evaporator)
With engine OFF, turn blower fan to “High” for at least 15 sec- MA
onds to dissipate any refrigerant trace in the cooling unit. Wait
a minimum of 10 minutes accumulation time (refer to the
manufacturer’s recommended procedure for actual waiting EM
time) before inserting the leak detector probe into the drain
hose. Keep the probe inserted for at least ten seconds. Use
caution not to contaminate the probe tip with water or dirt that LC
may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blow-
ing compressed air into area of suspected leak, then repeat EC
check as outlined above.
6. Do not stop when one leak is found. Continue to check for FE
additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start engine. CL
8. Set the heater A/C control as follows:
1) A/C switch ON.
2) Face mode
MT
3) Recirculation switch ON
4) Max cold temperature AT
5) Fan speed high
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps
PD
4 through 6 above.
AX
SU
Refrigerant leaks should be checked immediately after
stopping the engine. Begin with the leak detector at the BR
compressor. The pressure on the high pressure side will
gradually drop after refrigerant circulation stops and pres-
sure on the low pressure side will gradually rise, as shown ST
in the graph. Some leaks are more easily detected when
pressure is high.
RS
BT
SHA839E
11. Discharge A/C system using approved refrigerant recovery

equipment. Repair the leaking fitting or component as neces-
sary.
12. Evacuate and recharge A/C system and perform the leak test SC
to confirm no refrigerant leaks.
13. Conduct A/C performance test to ensure system works
properly. EL
IDX
HA-93
SERVICE PROCEDURE
Fluorescent Dye Leak Detector
Fluorescent Dye Leak Detector NMHA0286

PRECAUTIONS FOR FLUORESCENT DYE LEAK
DETECTION NMHA0286S01
I The fluorescent dye leak detector is not a replacement for an
electronic refrigerant leak detector. The fluorescent dye leak
detector should be used in conjunction with an electronic
refrigerant leak detector to pinpoint refrigerant leaks.
I For your safety and your customer’s satisfaction, read and fol-
low all manufacturer’s operating instructions and precautions
prior to performing the work.
I Refer to “Precautions for Leak Detection Dye”, HA-3.
CHECKING SYSTEM FOR LEAKS USING THE
FLUORESCENT LEAK DETECTOR NMHA0286S02
1. Check A/C system for leaks using the UV lamp and safety
glasses (J-42220) in a low sunlight area (area without windows
preferable). Illuminate all components, fittings and lines. The
dye will appear as a bright green/yellow area at the point of
leakage. Fluorescent dye observed at the evaporator drain
opening indicates an evaporator core assembly (tubes, core or
TXV) leak.
2. If the suspected area is difficult to see, use an adjustable mir-
ror or wipe the area with a clean shop rag or cloth, then check
the cloth with the UV lamp for dye residue.
3. Confirm any suspected leaks with an approved electronic
refrigerant leak detector.
4. After the leak is repaired, remove any residual dye using dye
cleaner (J-43872) to prevent future misdiagnosis.
5. Perform a system performance check and verify the leak repair
with an approved electronic refrigerant leak detector.
DYE INJECTION NMHA0286S03
(This procedure is only necessary when re-charging the system or
when the compressor has seized and was replaced.)
Refer to “Precautions for Leak Detection Dye”, HA-3.
1. Check A/C system static (at rest) pressure. Pressure must be
at least 345 kPa (3.52 kg/cm2, 50 psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye
into the injector (J-41459).
3. Connect the injector tool to the A/C LOW PRESSURE side
service fitting.
4. Start engine and switch A/C ON.
5. With the A/C operating (compressor running), inject one bottle
(1/4 ounce / 7.4 cc) of fluorescent dye through the low-pres-
sure service valve using dye injector (J-41459) (refer to the
manufacturer’s operating instructions).
6. With the engine still running, disconnect the injector tool from
the service fitting.
CAUTION:
Be careful not to allow dye to spray or drip when disconnect-
ing the injector from the system.
NOTE:
If repairing the A/C system or replacing a component, pour the
dye directly into the open system connection and proceed
with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix
HA-94
SERVICE PROCEDURE
Fluorescent Dye Leak Detector (Cont’d)
the dye with the system oil. Depending on the leak size, oper-
ating conditions and location of the leak, it may take from min-
utes to days for the dye to penetrate a leak and become visible. GI
MA
EM
LC
Belt
TENSION ADJUSTMENT NMHA0103
EC
I Refer to EM-16, “Checking Drive Belt”.
FE
CL
MT
Idle Air Control Valve (IACV) — Auxiliary Air
Control (AAC) Valve AT
INSPECTION NMHA0104
I Refer to EC-209, “System Description” and HA-14. PD
AX
SU
A/C Control System BR

REMOVAL AND INSTALLATION NMHA0290
1. Remove cluster lid C.
I Refer to BT-22, “Removal and Installation”. ST
2. Remove audio (radio).
3. Remove four screws of A/C control unit. RS
4. Disconnect A/C control unit harness connectors.
5. Remove A/C control unit.
6. Installation is the reverse order of removal. BT
ZHA028H
SC
EL
IDX
HA-95
SERVICE PROCEDURE
A/C Control System (Cont’d)
DISASSEMBLY NMHA0291
ZHA087H
Ventilation Air Filter

FUNCTION NMHA0268
Air inside passenger compartment is kept clean at either recircula-
tion or fresh mode by installing ventilation air filter into cooling unit.
NOTE:
To replace ventilation air filter, refer to MA-7, “PERIODIC
MAINTENANCE”.
Caution label is fixed inside the glove box.
RHA042G
REPLACEMENT PROCEDURE NMHA0269

1. Remove glove box.
2. Remove the instrument panel reinforcement. Refer to
“REMOVAL”, HA-89.
3. Remove filter cover fix clip.
4. Disconnect the thermal amp. connector.
ZHA082H
5. Slide the filter cover to the upper side and then remove it.
6. Remove the ventilation air filter from cooling unit.
7. Replace with new one and reinstall on cooling unit.
8. Reinstall filter cover, clip, instrument panel reinforcement and
glove box.
ZHA083H
HA-96
SERVICE PROCEDURE
Ventilation Air Filter (Cont’d)
9. Fill in the necessary details on the label and attach it to the
glove box in the position shown at left.
GI
MA
EM
ZHA084H LC
WASHING NMHA0294
1. Dip the filter into water containing detergent. EC
2. Move the filter gently to wash it.
3. Dip the filter into clean water to rinse it.
4. Dry the filter using shop air. FE
CAUTION:
I A dirty filter is the cause of mould and offensive odors.
CL
I The filter can only be washed and reused 1 to 2 times.
I If filter performance is not improved, replace the filter with
ZHA088H
a new one. MT
AT
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-97
SERVICE DATA AND SPECIFICATIONS (SDS)
Manual
Manual
COMPRESSOR NMHA0105
Model ZEXEL make DKV-11G
Type Vane rotary
Displacement
110 (6.71)
cm3 (cu in)/rev.
Direction of rotation Clockwise (viewed from drive end)
Drive belt Poly V
LUBRICANT NMHA0106
Model ZEXEL make DKV-11G
Name Nissan A/C System Oil Type R
Part number* KLH00-PAGR0
Total in system 180 (6.1, 6.3)

Capacity
m (US fl oz, Imp fl oz) Compressor (Service part) charging
180 (6.1, 6.3)
amount
*: Always check with Parts Department for the latest part information.
REFRIGERANT NMHA0107
Type HFC-134a (R-134a)
Capacity
0.45 - 0.55 (0.99 - 1.21)
kg (lb)
ENGINE IDLING SPEED (WHEN A/C IS ON) NMHA0108

I Refer to EC-225, “Idle Speed and Ignition Timing”.
BELT TENSION NMHA0109
I Refer to EM-16, “Checking Drive Belt”.
HA-98

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HEATER &

PRECAUTIONS ...............................................................2 A/C System................................................................30

Supplemental Restraint System (SRS) “AIR

General Refrigerant Precautions =NMHA0062

Precaution for Identification Label on Vehicle NMHA0272

Precautions for Refrigerant Connection NMHA0063

New 92471 N8210 6.8 (0.268) 1.85 (0.0728)

New 92472 N8210 10.9 (0.429) 2.43 (0.0957)

New 92473 N8210 13.6 (0.535) 2.43 (0.0957)

SHA814E New 92474 N8210 16.5 (0.650) 2.43 (0.0957)

Precautions for Service Equipment NMHA0065 BR

MANIFOLD GAUGE SET NMHA0065S04

SERVICE HOSES NMHA0065S05

SERVICE COUPLERS NMHA0065S06

CHARGING CYLINDER NMHA0065S08

Wiring Diagrams and Trouble Diagnoses NMHA0066

Special Service Tools NMHA0273

KV99231260 Removing shaft nut and clutch disc

KV992T0001 Removing clutch disc

KV992T0002 Installing pulley

KV99233130 Removing pulley

HFC-134a (R-134a) Service Tools and

KLH00-PAGR0 Type: Poly alkylene glycol oil (PAG), type R MT

Electrical leak detector Power supply:

(J-43926) Power supply:

(J-42220) UV lamp UV safety glasses Power supply: DC12V (Battery terminal)

(J-41447) Dye Application: For R-134a PAG oil

(J-43872) For cleaning dye spills.

Manifold gauge set (with Identification:

Service couplers Hose fitting to service hose:

Component Layout NMHA0071

Control Operation NMHA0072

FAN CONTROL DIAL NMHA0072S01

Discharge Air Flow NMHA0073

System Description NMHA0074

Component Location NMHA0085

Circuit Diagram — Air Conditioner NMHA0087

Wiring Diagram — A/C, Heater — NMHA0265

Wiring Diagram — A/C, M — NMHA0088

How to Perform Trouble Diagnoses for Quick

SYMPTOM TABLE NMHA0075S02

I Insufficient cooling. I Go to Trouble Diagnosis Procedure for Insufficient HA-43 PD

I Insufficient heating. I Go to Trouble Diagnosis Procedure for Insufficient HA-51

Operational Check =NMHA0076

2. Check Discharge Air NMHA0076S0202

6. Check Air Conditioner Switch NMHA0076S0206

*1: HA-31 *2: HA-28 *3: HA-21

2 CHECK BODY GROUND CIRCUIT FOR A/C CONTROL UNIT

*1: HA-33 *2: HA-28 *3: HA-27

SYSTEM DESCRIPTION NMHA0136

2 CHECK FOR A/C CONTROL UNIT OUTPUT

CONTROL LINKAGE ADJUSTMENT NMHA0093

*1: HA-38 *2: HA-28 *3: HA-27

2 Approx. 0.27 - 0.33Ω

4 Approx. 2.25 - 2.75Ω

1 Fan fails to rotate.

2 Fan does not rotate at 1-speed.

3 Fan does not rotate at 2-speed.

4 Fan does not rotate at 3-speed.

1: HA-31 2: HA-28 *3: HA-21

1: HA-33 2: HA-28 *3: HA-27

1: HA-38 2: HA-28 *3: HA-27

1: HA-46 3: HA-47 *4: HA-52

1: HA-58 2: HA-54 *3: HA-28

1: HA-64 3: HA-27 *5: HA-63

1: HA-82 3: HA-79 *4: EM-16